Bipolar electronics package

ABSTRACT

A sealed electronics package comprising a tubular case wall including first and second conductive portions electrically separated by an insulative partition, a hermetic seal between the insulative partition and the first conductive portion, a hermetic seal between the insulative partition and the second conductive portion, wherein the first conductive portion is an anode and said second conductive portion is a cathode, end caps; and a hermetic seal between the end caps to the tubular case wall.

REFERENCE TO PRIOR FILED APPLICATIONS

[0001] This application is a Continuation-in-Part of co-pending application Ser. No. 09/774,450, filed Jan. 30, 2001, which claims priority to U.S. provisional application No. 60/179,764, filed Feb. 20, 2000; and is a Continuation-in-Part of co-pending application Ser. No. 09/842,790, filed Apr. 25, 2001, which claims priority to U.S. provisional application No. 60/199,893, filed Apr. 26, 2000, the entirety of each of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

[0002] This invention relates to an electronics package design and more particularly to a case design for devices such as batteries and capacitors that require separation of electric polarity.

BACKGROUND OF THE INVENTION

[0003] In typical electronics packaging such as a capacitor or the battery case 10 shown in FIG. 1, separation of polarity is achieved by using a sealed feedthrough 5 that includes a feedthrough pin 1, feedthrough insulator 2, and feedthrough body 3. The feedthrough body is one polarity and is insulated from the feedthrough pin, which is of opposite polarity. The feedthrough acts to carry the charge from the internal components of the battery to outside the battery. Feedthrough technology is well known, and feedthroughs can be designed in a variety of dimensions and materials. One of the design criteria for the typical feedthrough is that its length must be sufficient to form a hermetic seal within itself and to the battery case lid 6, which is hermetically sealed to the battery case body 7. This length takes up precious space in the internal volume of the sealed package or adds to the external geometry of the case. In either instance, volume is sacrificed for nonactive components of the package.

SUMMARY OF THE INVENTION

[0004] The package of the present invention minimizes this ineffective volume by incorporating the function of the feedthrough into a tubular case wall. The case is constructed by interposing an insulative partition between two conductive portions of the tubular case wall to electrically separate the two conductive portions, allowing each portion to have a different polarity. This allows the positive polarity components of the battery to be electrically connected to one portion of the tubular case wall and the negative polarity components to be connected to a separate portion of the tubular case wall, carrying the charge to the outside of the battery through the tubular case wall, thus eliminating the need for a separate feedthrough. By this invention, a single sealed chamber is created with a minimum of wasted space.

[0005] Battery assembly is simplified with this invention. First, the electrodes along with the separator are wound around a mandrel to form a “jellyroll”. The electrodes have tabs extending from them that will be later attached to the case. The tabs from the positive electrode extend in opposite direction of the tabs from the negative electrode. The jellyroll is then inserted into the bipolar case with the tabs extending outside of the case. One end cap is then fit into place, sandwiching the tabs in the interface between the case and the end cap. The end cap is then laser welded to the case, simultaneously connecting the tabs to one end of the case. The battery is then filled with electrolyte from the open end of the case. After filling, the other end cap is positioned and hermetically sealed with the sandwiched tabs in the end cap—tubular case wall interface. The battery is then sent to undergo formation cycling. For the battery of the present invention, to be considered hermetic, the seals must have a leak rate of less than 10⁻⁸ atm-cc/sec He.

[0006] In a variation of the invention, the insulative partition forms substantially the entire tubular case wall, with end caps carrying the charge. The tabs are sandwiched between the end caps and metal rings, which are hermetically sealed to the insulative partition.

BRIEF DESCRIPTION OF THE FIGURES

[0007]FIG. 1 is a section view of a prior art feedthrough subassembly, a battery case, and a case cover.

[0008]FIG. 2A is a plan view of the electronics package of the present invention.

[0009]FIG. 2B is a plan view of the jellyroll formed by the electrodes and separator of the present invention.

[0010]FIG. 2C is a plan view of the jellyroll inserted within the case of the present invention.

[0011] FIGS. 3A-3I are plan views of an alternative embodiment of the electronics package of the present invention.

[0012] FIGS. 4-6 are exploded views of other alternative embodiments of the bipolar electronics package of the present invention.

DETAILED DESCRIPTION

[0013] The following text describes the preferred mode presently contemplated for carrying out the invention and is not intended to describe all possible modifications and variations consistent with the spirit and purpose of the invention. The scope of the invention should be determined with reference to the claims.

[0014] As shown in FIGS. 2A-2C, the case 20 is constructed by interposing an insulative partition 23 between two conductive case portions 22, 24 of the tubular case wall to electrically separate them, allowing them to have two different polarities. This allows the positive polarity components of the battery to be electrically connected to one portion of the tubular case wall and the negative polarity components to be connected to a separate portion of the tubular case wall. The charge is carried to the outside of the battery through the tubular case wall, thus eliminating the need for a separate feedthrough.

[0015] The insulative partition 23 preferably is ceramic such as glass, aluminum oxide, or zirconium oxide but may alternatively comprise a polymer, and preferably has the same inside and outside diameters of the conductive case portions 22, 24. However, it may be desirable for strength to provide a slightly thicker insulative partition than the conductive case portion; to maximize the internal volume, it is preferred that the insulative partition not extend into the internal volume more than 100% of the conductive case portion wall thickness beyond the conductive case portion. The conductive case portion preferably has a thickness of 0.3 to 0.8 mm, and preferably about 0.5 mm, and the insulative partition preferably has a wall thickness of about 0.3 to 1 mm. The insulative partition 23 may be mechanically attached to the separate conductive case portions by brazing, welding, or other mechanical attachment method, preferably forming a hermetic seal. The insulative partition 23 preferably has a width of at least 1 mm to ensure that conductive case portions 22 and 24 are electrically separated and not shorted during manufacturing such as by forming a bridge with brazing material.

[0016] A variety of materials can be chosen for the case; however, the materials' coefficients of thermal expansion (CTE), dimensions, and assembly methods must be considered in combination and chosen to prevent cracking. The chemistry of the electrolyte and active electrode materials is also important when choosing case materials. The electrolyte may be liquid, such as a lithium salt dissolved in a mixture of a nonaqueous liquid solvent, or may be gel or solid polymer. For lithium-ion batteries, Ti-6-4, other Ti alloys, Al, Al alloys, and 300 series stainless steels are especially suitable for the positive conductive case portions and end caps, and CP Ti, Ti alloys, Cu, Al, Al alloys, Ni, Pb, and stainless steels are especially suitable for the negative conductive case portions and end caps.

[0017] The insulative material is preferably a ceramic, and most preferably zirconium oxide, to provide strength. Alternatively, the insulative material may comprise a plastic or nonconductive carbon-loaded plastic composite. The wall strength of the case having a thin ceramic ring in the middle may be increased by bonding a supporting material across the ceramic-metal joints with a nonconductive adhesive, either on the inside or outside of the battery case, or both.

[0018] If a braze is used to attach the insulative partition to the conductive case portions, a braze material is chosen that can withstand contact with the electrolyte at high potentials without corroding; it is preferably Au-based, with a high % Au for electrochemical stability. Optionally, the braze may be protected from the electrolyte with a protective covering, which may comprise a polymer such as parylene, polyimide, polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), styrene butadiene rubber (SBR), acrylic resin, epoxy resin, or urethane resin, or a metal such as gold, platinum, or aluminum, on top of the brazing material to prevent corrosion at high voltage in electrolyte. This is particularly advantageous for the positive side of the case. The protective covering may be applied by vapor deposition, plating, coating, or the like. A metallic covering of gold or the like may be advantageously deposited on the braze without sticking to the ceramic, thereby ensuring that a bridge is not inadvertently formed across the ceramic insulative partition.

[0019] In typical battery designs, some of the internal volume of the battery is reserved to make the internal attachment from the wound electrodes to the feedthrough pin. This inactive volume or “headspace” decreases the energy density of the battery. With the bipolar electronics package of the present invention, the headspace is virtually eliminated.

[0020] Furthermore, battery assembly is simplified with this inventive package. As shown in FIG. 2B, the negative electrode 34, separator 33, and positive electrode 32 are wound around a mandrel (not shown) to form a “jellyroll” 30. The positive electrode has one or more tabs 31 and the negative electrode 34 has one or more tabs 35 that will be later attached to the case 20. The tabs 31 of the positive electrode 32 extend in opposite direction to the tabs 35 of the negative electrode. The positive tabs 31 are preferably aluminum or an aluminum alloy, and the negative tabs 35 are preferably nickel or a nickel alloy or titanium or a titanium alloy.

[0021] As shown in FIG. 2C, the jellyroll 30 is inserted into the case 20 with the tabs extending outside of the case. A first end cap 41 is then fit into place, sandwiching the first set of tabs (negative or positive) in the interface between the case 20 and the first end cap 41. The first end cap is then laser welded to the case, simultaneously connecting the first set of tabs to the first end of the case.

[0022] As an alternative to extending the tabs outside of the case and then sandwiching them between the case and the end cap, the tabs may be first welded to the inside of the case 20 before installing the end cap 41.

[0023] The battery is then filled with electrolyte from the opposite, open end of the case. After filling, a second end cap 45 is positioned and hermetically sealed with the second set of tabs sandwiched in the end cap—tubular case wall interface. The battery then undergoes formation cycling.

[0024] The technique of sandwiching positive electrode tabs between a tubular case wall and end cap has been described earlier in pending U.S. application Ser. No. 09/842,790 entitled, “LITHIUM BATTERY SUITABLE FOR HYBRID ELECTRIC VEHICLES,” which is assigned to the assignee of the present invention and is incorporated herein by reference.

[0025] The battery of this design is ideally used with spring contacts contacting the end caps. Alternatively, the end caps do not necessarily need to be flat, and may have features drawn in, welded on, or otherwise coupled to them for electrical connection to provide power to a device. Furthermore, the end caps may be of different physical characteristics, such as geometry for devices in which polarity matters to avoid incorrect installation. For example, one end may be square and the other round.

[0026] In an alternative embodiment shown in FIGS. 3A-3I, the insulative partition 53 forms substantially the entire tubular case wall, with end caps 51 and 55 carrying the charge. Metal rings 52 and 54 are hermetically sealed to the ends of insulative partition 53. The tabs of the electrodes in the electrode assembly 56 are sandwiched between the metal rings 52 and 54 and the end caps 51 and 55. In FIGS. 3A-3C, metal rings 52 and 54 are illustrated as simple washers and end caps 51 and 55 are illustrated as simple disks. However, other structures may be used for the metal rings and the end caps, as shown in FIGS. 3D-3I. For these configurations where the end cap is being inserted within a hole in the metal ring, as opposed to merely being welded to a flat surface as in FIGS. 3A-3C, it is preferable that the end cap be slightly tapered for ease of insertion into the hole.

[0027] In an alternative embodiment shown in FIG. 4, insulative partition 43 may be sealed to conductive case portions 42 and 44 by mating threads 46, 47, 48, and 49. In that case, insulative partition 43 is preferably plastic. End cap 41 and conductive case portion 42 sandwich electrode tabs 31, and end cap 45 and conductive case portion 44 sandwich electrode tabs 35 of jellyroll 30.

[0028] As shown in FIGS. 5A and 5B, this invention may take on a variety of forms, including those having elliptical (FIG. 5A) or rectangular (FIG. 5B) cross sections. The invention is not limited to use with a jellyroll-type electrode assembly. As shown in FIG. 6, the insulative partition 83 may be used to separate tubular case wall portions 82 and 84 in a battery having a stacked electrode configuration 86. Positive electrodes within the stack include tabs 87, which are sandwiched between tubular case wall portion 82 and end cap 81. Negative electrodes within the stack include tabs 88, which are sandwiched between tubular case wall portion 84 and end cap 85.

[0029] In noncylindrical stacked batteries in which a rigid ceramic insulative partition forms the entire tubular case wall and in which the stack is oriented such that it exerts force on the end caps, it is especially important that the end caps be flexible enough to allow for expansion and contraction during battery cycling. This may be accomplished by choice of materials, material thickness, and configuration.

[0030] The invention herein has been described by examples and a particularly desired way of practicing the invention has been described. However, the invention as claimed herein is not limited to that specific description in any manner, and numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. Furthermore, the features described for one embodiment may be combined with other embodiments herein disclosed. Equivalence to the description as hereinafter claimed is considered to be within the scope of protection of this patent. 

What is claimed is:
 1. An electronics package comprising: a tubular case wall including: first and second conductive portions electrically separated by an insulative partition; a first seal between said insulative partition and said first conductive portion; a second seal between said insulative partition and said second conductive portion; wherein said first conductive portion is an anode and said second conductive portion is a cathode; end caps; and third and fourth seals between said end caps and said tubular case wall; wherein said electronics package forms a single sealed chamber.
 2. The package of claim 1 and further including means to energize said first and second conductive portions, wherein said means includes: at least one positive electrode and at least one negative electrode separated by at least one separator; and an electrolyte.
 3. The package of claim 1 wherein said electronics package is a battery.
 4. The package of claim 1 wherein said insulative partition has a width greater than 1 mm.
 5. The package of claim 1 wherein said insulative partition comprises zirconium oxide.
 6. The package of claim 1 wherein said second conductive portion comprises a material chosen from the group consisting of stainless steel, aluminum and alloys thereof, and titanium and alloys thereof.
 7. The package of claim 2 wherein said at least one positive electrode comprises at least one positive tab, said positive tab made of stainless steel, Ti-6Al-4V, aluminum, or an aluminum alloy.
 8. The package as in claim 2 wherein said at least one negative electrode comprises at least one negative tab, said negative tab made of titanium, nickel, or an aluminum alloy.
 9. The package as in claim 8 wherein said insulative partition is hermetically sealed to said conductive portions using a braze.
 10. The package as in claim 9 wherein said braze comprises a gold-based brazing material.
 11. The package as in claim 9 wherein said package includes an electrolyte and said braze is covered with a protective coating inert to said electrolyte.
 12. The package as in claim 11 wherein said protective coating comprises a polymer chosen from the group consisting of: parylene, polyimide, PTFE, PVDF, styrene butadiene rubber, acrylic resin, epoxy resin, and urethane resin.
 13. The package as in claim 11 wherein said protective coating comprises a metal chosen from the group consisting of: gold, platinum, and aluminum.
 14. The package as in claim 1 wherein said seal between said first, second, third, and fourth seals are hermetic seals.
 15. The package as in claim 1 wherein said insulative partition is plastic and wherein said first and second seals comprise threaded connections.
 16. A sealed outer case consisting of: a first conductive portion; a second conductive portion; an insulative partition made from a ceramic selected from the group consisting of glass, aluminum oxide, and zirconium oxide, said insulative partition interposed between said first conductive portion and said second conductive portion wherein said first and second conductive portions are made of metal selected from the group consisting of stainless steel, aluminum alloys, titanium and alloys thereof; a first seal between said first conductive portion and said insulative portion; and a second seal between said second conductive portion and said insulative portion.
 17. The outer case of claim 16 wherein said first conductive portion consists of a first end cap and a first metal ring and wherein said second conductive portion consists of a second end cap and a second metal ring.
 18. The outer case of claim 16 wherein outer case undergoes expansion and contraction and wherein said first and second end caps are sufficiently flexible to allow for expansion and contraction without damaging said first and second seals.
 19. The outer case of claim 16 wherein said first and second seals are hermetic seals.
 20. A method for making a sealed bipolar electronics package comprising the steps of: providing case components including a positive end cap, a negative end cap, and a tubular case wall having an insulative partition; providing at least one positive electrode and at least one negative electrode, the positive electrode having positive tabs extending therefrom and the negative electrode having negative tabs extending therefrom; positioning the positive and negative electrodes with the positive tabs extending in a different direction from the negative tabs and separating the positive and negative electrodes with at least one separator to form an electrode assembly; inserting the electrode assembly into the case with the positive tabs extending from one end of the case; sandwiching the positive tabs between the case and the positive end cap; welding the positive end cap to the case while connecting the positive tabs to the positive end cap; filling the case with electrolyte; sandwiching the negative tabs between the case and a negative end cap; and welding the negative end cap to the case while connecting the negative tabs to the negative end cap.
 21. The method of claim 20 wherein said step of providing case components further includes providing the tubular case wall having a negative conductive portion and a positive conductive portion hermetically sealed to and electrically separated by the insulative partition.
 22. The method of claim 20 and further comprising the step of: winding the positive electrode, separator, and negative electrode around a mandrel to form a jelly roll.
 23. The method of claim 20 wherein said welding step comprises using a filler material to join and seal the components.
 24. The method of claim 20 wherein and further comprising the step of: covering the filler material with a protective coating inert to said electrolyte.
 25. The method of claim 24 wherein said covering step comprises: covering the filler material with a polymer chosen from the group consisting of: parylene, polyimide, PTFE, PVDF, styrene butadiene rubber, acrylic resin, epoxy resin, and urethane resin.
 26. The method of claim 24 wherein said covering step comprises: covering the filler material with a metal chosen from the group consisting of: gold, platinum, and aluminum. 